Welding generator



May 16, 1950 J. H. BLANKENBUEHLER 2,508, 0

WELDING GENERATOR Filed Dec. 29, 1945 fi pereg /5 a m o 2 00 3 00 Hm aeras WITNESSES: INVENTOR 6 Q Jbbfl rifi/anxenue/v/er:

ATTONEY Patented May 16, .1950

WELDING GENERATOR John H. Blankenbuehler, Murrysville, Pm, as-

signor to Westinghouse Electric Corporation, East Pittsburgh, Pa., a corporation of Pennsylvania Application December 29, 1945, Serial No. 638,358

My invention relates, generally, to generators and it has reference, in particular, to control systems for arc welding generator of the crossfield type such as may be used for are weldin and the like.

Generally stated, it is an object of my invention to provide an arc welding generator which is simple and inexpensive to manufacture and which is easy to operate.

More specifically, it is an object of my invention to provide for improving the operating characteristics of generators of the cross-field type.

Another object of my invention is to provide for varying the output current of arc welding generators of the cross-field type without adversely affecting the open circuit voltage of the generator.

Yet another object of my invention is to provide for shifting the position of the volt-ampere curve of generators of the cross-field type without materially reducing the open circuit voltage.

It is also an object of my invention to provide for using an auxiliary field windin for increasing the open circuit voltage of a generator of the cross-field type when the impedance of the auxiliary brush circuit is increased to provide a lower value of arc welding current.

Other objects will, in part, be obvious and will, in part, be explained hereinafter.

In practicing my invention in one of its forms, a generator of the cross-field type is provided with resistance means for varying the impedance of the auxiliary brush circuit for the purpose of providing difierent values of current in an arc welding circuit. An auxiliary field winding is provided on one of the field poles and a control switch is used to simultaneously connect the auxiliary field winding and the resistance means in the auxiliary brush circuit of the generator in series and series parallel relations. The characteristic volt-ampere curve of the generator may thus be altered in difierent degrees to vary the value of the welding current without reducing the open circuit voltage below a value at which an arc may be easily struck.

For a more complete understanding of the nature and scope of my invention, reference may be made to the followin detailed description which may be studied in connection with the accompanying drawing, in which:

Figure 1 is a diagrammatic view of an arc welding system embodying the invention in one of its forms;

Fig. 2 is a diagrammatic view of an arc weld- 6 Claims. (Cl. 322-92) ing system embodying the invention in another of its forms;

Fig. 3 is a diagrammatic view of an arc welding system embodying the invention in a diflerent form;

Fig. 4 shows a plurality of volt-ampere or load characteristic curves illustrating the prior method of varying the output characteristics by varying the impedance of the auxiliary brush circuit;

Fig. 5 shows a plurality of volt-ampere or load characteristic curves illustrating the method of varyin the output by means of the system shown in Figs. 1 and 2; and

Fig. 6 shows a plurality of volt-ampere or load characteristic curves illustrating the method 01' varying the output characteristic of the generator in the system of Fig. 3.

The present invention is an improvement over the invention disclosed in Patent No. 2,342,720,

. which issued to me on February 9, 1944. While the generator shown in the above-mentioned patent is illustrated as having both a sliding magnetic shunt as well as switch means for controlling the connections of a control resistor in the auxiliary brush circuit for varying the output characteristics of the generator, the generator in the present invention is shown, for purposes of simplification, as having only the switch means and control resistor for varying the output characteristics. It will be understood, however, that the present invention may be used with either method of current control or with both methods, as well as with other systems of control wherein variations of the ouput characteristics normally result in reduced open circuit voltage.

Referring to Fig. 1, the reference numeral l0 may. denote, generally, an arc welding system wherein a generator I: of the cross-field type is disposed to provide welding current to work l3 and an arc welding electrode I4.

The generator [2 may comprise an armature l5 having pairs of main brushes I6 and auxiliary brushes l'l positioned along axes which are substantially ninety electrical degrees apart. The main brushes I6 may be positioned along the longitudinal axis of a main field winding it which may be connected in circuit relation with the main brushes, work l3 and electrode It. Control means '20 comprising a rectifier circuit 2| and a reversing switch 22 may be provided in connection with the main field winding I9 for supplying a unidirectional currentthereto for determining the polarity oi. the work l3 and electrode l4.

In order to provide for varying the output characteristics or the generator l2, a. control resistor 24 may be provided having end ter-' minals 25 and 28 with an intermediate tap 21 positioned therebetween. Instead of merely connecting the control resistor 24 in series circuit relation with the auxiliary brushes H, which would result in a family of volt ampere curves A, .B and C such as shown in Fig. 4 when the auxiliary brushes II are short-circuited and when one or two sections of the control resistor are connected in series circuit relation with the auxiliary brushes, provision may be made for connecting an auxiliary field winding 28 between the auxiliary brushes IT in conjunction with the control resistor 24.

The auxiliary field winding 28 may be positioned on either of the field poles of the generator and may be so connected as to be cumulative with respect to the main field winding IS. A multi-position switch 30 may be provided having a movable arm 2| which may be connected to the terminal 25 of the control resistor 24 and to the lower one of the auxiliary brushes H. The auxiliary field winding 2| may be connected between the upper one of the auxiliary brushes I1 and the intermediate tap 21 of the control resistor. The movable arm ii of the switch 30 may be connected to either the terminal 26 of the control resistor or a stationary contact 32 which may be connected to the junction of the auxiliary field winding 28 with the upper one of the auxiliary brushes IT.

with the movable arm 3| engaging the stationary contact 32, the auxiliary brushes ll are short-circuited and the auxiliary field winding 2| and control resistor 24 are disconnected from the circuit. As shown in Fig. 5, the volt ampere curve-of the generator l2 may be represented by the curve A, which is identical with the curve A shown in Fig. 4, since in both instances the auxiliary brushes of the generators are short-circuited'.

When the movable arm is connected to the terminal 26, the two sections of the control resistor on either side of the intermediate tap 21 are connected in parallel circuit relation and in series circuit relation with the auxiliary field winding 28 between the auxiliary brushes l1. Accordingly, the output characteristic of the generator under these conditions may be represented by the curve B of Fig. 5.

Since the field winding 28 is cumulative with respect to the main field winding IS, the open .circuit voltage of the generator is increased from approximately 42 to 63 volts so that it is substantially identical with the open circuit voltage of the curve A. Because the magnetic circuit of generators of the cross-field type is substantially saturated throughout the entire operating range, the cumulative effect oi! the auxiliary field winding 28 will not be noticed under load conditions. Accordingly, the major portion of the curve B is substantially identical with the principal portion of the curve B.

When the movable arm 3| is moved to the position shown, the auxiliary field winding 28 is connected in series circuit relation with the auxiliary brushes l1 and the portion of the control resistor 24 between the intermediate tap 21 and the terminal 25. Since the impedance of the circuit is increased over that previously described in connection with the characteristic curve B,

the output characteristic may be represented by the curve 0'. Since the increase of resistance in the auxiliary brush circuit produces the current therein, the eii'ect of the auxiliary winding 2| is not as noticeable as in the case of-the curve B. Accordingly, the open circuit voltage may be reduced somewhat to a value of approximately 43 volts. Throughout a major portion of the curve C, the curve coincides with the curve C of Fig. 4. Because of the auxiliary field winding 2|, however, the open circuit voltage is increased irom a value 01' approximately 22 volts to a value of approximately 43 volts. This increase greatly improves the stability of the arc and greatly'iacllitates the striking of the arc.

Referring to Fig. 2, the reference numeral 4| may denote, generally, .an arc welding system wherein a generator i2 oi the cross-field type having main brushes i8 and auxiliary brushes II is connected for supplying welding current to an arc welding circuit including work l2 and an electrode i4. The generator may be provided as hereinbefore with the main field winding l9 and polarity control means 2| for controlling the terminal polarity of the generator.

In this embodiment of the invention, the auxiliary field winding 2| and the control resistor 24 may likewise be connected in circuit relation with the auxiliary brushes II by means of a multiposition switch 42. The switch may comprise a movable contact arm 4| connected to the lower one of the auxiliary brushes for selectively engaging stationary contact members 44, 45 and 46, which may be connected to the upper one 0! the auxiliary brushes H, to the intermediate tap 21, and tothe terminal 25 of the control resistor 24 respectively. The auxiliary field winding 2| may be connected between the upper one of the auxiliary brushes l1 and the terminal 2| 0! the control resistor.

With the movable arm 42. engaging the stationary contact member 44, the auxiliary brushes I! will be short-circuited and the output characteristic of the generator will conform to the curve A of Fig. 5. With the contact arm 4| engaging the stationary contact 45, one section of the control resistor 44 is connected in the auxiliary brush circuit in series circuit relation with the auxiliary winding 28 so that the output characteristic oi the generator conforms to the curve B of Fig. 5. With the movable contact arm 4| in the-position shown, both sections of the control resistor are connected in series circuit relation with the auxiliary field winding 2| and the auxiliary brushes I! so that the output characteristic of the generator conforms generally to the curve C o! Referring to Fig. 3, the reference numeral ll denotes, generally, an arc welding system wherein an arc welding generator [2 oi. the cross-field type having main brushes II and auxiliary brushes i1 is provided with arnain field winding I| connected in series circuit relation with the main brushes for providing welding current to an arc ,welding circuit including a work piece II and electrode l4. Polarity control means 2| may be provided in conjunction with the main field winding it for selectively determining the terminal polarity of the work piece l2 and electrode [4.

A control resistor 24 may be provided, as hereinbefore, for changing the volt ampere or characteristic curves of the generator to provide different values of welding current. Instead of utilizing a single auxiliary field winding 2| in conjunction with the control resistor 24. auxiliary field windings 2| and 2| may be provided. Both of these windings may be arranged for connection in cumulative relation with the main field winding is in the auxiliary brush circuit by means 01 a control switch I having a movable contact arm Ill for selectively engaging a plurality of stationary contact members ll, II and 56.

With the movable contact arm 53 engaging the stationary contact member 54, the auxiliary brushes II are short-circuited and the output characteristic of the generator may be represented by the curve A of Fig. 6, which is identical with the curve A of Figs. 4 and 5.

When the movable contact arm 53 engages the stationary contact member 55, the auxiliary field winding 28 is connected in series circuit relation with the auxiliary brushes I1 and the sectionot the control resistor 24 between the terminal 26 and the intermediate tap 21. Accordingly, the

' output characteristic oi the generator may be represented by the curve B' of Fig. 6, which is identical with the curve B of Fig. 5.

The eiiect of the auxiliary field winding in raising the open circuit voltage is substantially the same as that for the systems of Figs. 1 and 2. However, with the movable contact arm 53 engaging the stationary contact member 5|, both the auxiliary field windings it and 28' are now connected in series circuit relation with the auxiliary brushes i1 and both sections of the control resistor 2|.

Accordingly, the output characteristic of the generator represented by the curve C", shown in Fig. 6, illustrates the effect of the auxiliary field winding 28 in further boosting the open circuit voltage. The open circuit voltage is now approximately 55 volts instead of the 43 volts shown in Fig. 5 and the 22 volts of the uncompensated generator shown in Fig. 4.

From the above description and the accompanying drawing, it will be apparent that I have provided in a simple and effective manner for improving the operating characteristics of generators of the cross-field type. Instead of varying the current output and reducing the open circuit voltage each time the output current is reduced as has been the case with the systems of the prior art, I have provided for so controllin the output characteristics of the generators as to permit decreasing the value of welding current without appreciably reducing the open circuit voltage.

Since it has been determined by experience that the open circuit voltage of a welding generator had a definite eil'ect on the ease of striking the arc, it is extremely important to insure maintaining the open circuit voltage above the predetermined value, regardless of the current setting for which the generator may be adjusted. With an open circuit voltage of 60 volts or thereabouts, little difliculty is ever encountered in striking an are but when the open circuit voltage is reduced below approximately 40 volts, difficulty is frequently encountered in striking an are, particularly if the work does not have a clean or oxidized surface.

Accordingly, by providing for maintaining substantial-y the full open voltage of the generator since certain changes may be made in the above-described construction and diilerent embodiments of the invention may be made without departing from the spirit or scope thereof,

it is intended that all the matter contained in the above description and shown in the accompanying drawing shall be considered as illustrative and not in a limiting sense.

I claim as my invention; 1. For use with a generator of the cross-field type having main and auxiliary brushes, a resistor having end terminals and an intermediate tap, an auxiliary field winding, circuit means connecting the auxiliary field winding in series able to another position to connect the two end terminals of the resistor to one of the auxiliary brushes.

2. Control means for an arc welding generator of the cross-field type having an armature with when adjusted for the maximum current output,

main and auxiliary brushes and a main field winding having its axis along the axis of the main brushes comprising, a control resistor having a pair of end terminals and an intermediate tap, an auxiliary field winding connected between one terminal of the resistor and one of the auxiliary brushes cumulatively relative to the main field winding, and a multiposition switch having a movable arm connected to the other of the auxiliary brushes, said switch being operable to difierent positions to provide a circuit to the other terminal of the resistor. to the intermediate tap, or to the said one of the auxiliary brushes.

3. In a generator of the cross-field type, an

armature having main and auxiliary brushes po sitioned along axes ninety electrical degrees apart, a main field winding having its longitudinal axis substantially along the axis of the main brushes, said winding being connected in series circuit relation with the main brushes, an auxiliary field winding having its longitudinal axis substantially-along the axis of the main field winding, a control resistor, and circuit means connecting the auxiliary field winding and the control resistor in circuit rellilajign with the auxiliary brushes to lower the c nt output of the generator without substantially reducing the open circuit voltage of the generator.

4. A generator of the cross-field type comprising, an armature having main and, auxiliary brushes, a main field windingconnected in circuit with the main brushes, resistance means comprising a plurality of sections, an auxiliary field winding having a like plurality of sections. and circuit means including a multiposition switch operable to difierent positions to connect one or more of said resistance sections and winding sections in circuit with the auxiliary brushes,

whereby the output current or the main brushes is reduced in difierent amounts without appreciably reducing the open circuit voltage of the main brushes.

5. In a generator of the cross-field type having an armature with main and auxiliary brushes and a main field winding connected in series circuit relation with the main brushes disposed along the axis of the main brushes, a resistor, an auxiliary field winding disposed axially oi the main field winding, and switch means selectively operable to connect the resistor in circuit with the auxiliary brushes to vary the current outfield winding in circuit with the auxiliary brushes in cumulative relation with the main field winding to prevent the resistor from materially reduclng the open circuit voltage at the main brushes.

6. In combination with a generatorot the type having a main field winding and an armature with main and auxiliary brushes positioned along the axis of the main field winding and along an axis ninety electrical degrees therefrom, a resistor, an auxiliary field winding disposed with its axis substantially along the axis of the main field winding, and circuit means including a switch operable to connect different portions of the resistor in circuit with the auxiliary brushes to pro duce volt ampere characteristic curves of lower 8 current values, said switch being eflective to connect the auxiliary field winding in circuit with the auxiliary brushes and said different portions of the resistor to shift a P rtion of the volt ampere curves and increase the open circuit voltafle.

' JOHN H. BLANKENBUEHLER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 1 Number Name Date 458,618 Clark Sept. 1, 1891 2,227,678 Stiles June I, 1941 2,394,049 Fisher Feb. 5, 1946 

